Hat construction



J. M. MAY LE ASQ HAT CONSTRUCTION. APPLICATION FILED JUNE 10. 1921 1,412,479.] I Patented M1211, 1922.

u I v W/f/VESSES INVENTOR QIOLSEPH Z'Zq )(L'EAQ'.

- ATTORNEYS JOSEPH M. MAYLEA S, O'FNEW YORK, N. Y.

HAT CONSTRUCTION.

Application filed June 10, 1921.

T 0 all whom it may concern:

Be it known that I, JOSEPH M. MAYLEAs, a citizen of Latvia, and a resident of the cit of New York, borough of Manhattan, in the county and State of New York, have invented a new and Improved Hat Construction, of which the following is a full, clear, and exact description.

This invention relates to hat constructions,

and has for an object the provision of a new.

and improved double or cushion brimfor hats, which brim can be very simply, eflicientl and economically manufactured with consi erable saving in material over the old method of making brims for hats of the type to which this invention appertains.

Another object resides in the provision of a brim construction, with special reference to a double brim which can be readily manufactured and associated with a cover of some suitable fabric of the nature of plush or felt or other fabric having a minimum amount of-seam, whereby the appearance ofthe 'hat is reatly improved.

further object resides in the provision of a brim in which the outer edge is rolled over or blocked in a smooth curve and in which the cover fabric on the edge presents a smooth, finished appearance on the lower surface of the brim as well as on the upper.

A still further object resides in the provision of means whereby the cover for the brim may be placed on with a mlnimurn' amount of labor and a minimum likelihood of the formation of wrinkles by stretching the cover on the frame.

The invention is illustrated in the draw i ings, of which Figure 1 is a partial vertical section through a hata f Figure 2 is an inverted plan view of the rim;

the brim at one stage in the process of its manufacture;

Figure 4 is a view of the body portion of the brim at a later stage in its manufacture; and

Figure 5 is a detail view illustrating the Specification of Letters Patent.

Patented Apr. 11, 1922. Serial No. 476,462.

covered with body shape,

plush. Thishat may have a portion or crown 1 ofany desired covered preferably with plush and provided with. the usual band 2 as well as the usual 'lining3. It is customary in the construction of hats of this and similar forms to turn the inner edges of the brim upward as shown at 4 and turned edges 4 between the lower ends of.the crown and the'lining.

In accordance with my invention, the brim shown in the drawings is formed of any material suitable 'for making brims, such as buckram, which is cut out in the proper shape initially, asshown in Fig. 3, with central apertures 5 and up-turned flange portions 6 and 6 surrounding these apertures. main portion of the brim is made of a sheet The' to suitably fasten the upof fabric bent over to form a double layer 7 and 8 joined together by a smooth, curved .rim portion 9 and spaced apart excepting at their inner edges 9 and 10, which are later, when the hat is assembled, drawn close together. This form of the brim body portion, as'shown in Fig. 3, is made over any suitable forming mandrel or block, as is customary in this industry. After thus being formed, the lower flange 6' is cut oil, as shown in Fig. 44, leaving the upper flange 6 intact-. While still on the block this brim body or backing is covered with a layer of plush or similar material. This sheet of covering material for the brim is joined by a seam which, as shown in F 5 by the numeral 11, is cut on the bias so as to permit the material to be stretched smoothly and evenly over the curved brim body portion without the formation of wrinkles.

In Fig. 2 I show in dotted lines the substantially radially extending seam 12 formed between the adjacent edges of the fabric or body portion of the rim, and which edges Figure 3 is a view of the body portion-of lush'or other material is placed over the rim,'it, during t shape shown in and 8 are most widely spaced apart at the rim 9 and then gradually approach each other at their inner ends. As mentioned above, the up-turned ed es of the plushand the flange is process, has assumed the 6 are dispose between thelower ends of the lining and the crown and are suitably connected therebetween.

ig. 1 in which the layers 7 In this manner I- provide a new and inn It will thus be manifest that I have provided a hat which has a stifi foundation of buckr'am or the like and which maybe provided-with a cloth covering of any suitable material, and further, that the-brim is essentially .a cushion, brim as knpwnin" the art at this time, the same being of tubular or channel shaped cross section to produce the hollow or shell-likelformation as described a with a hollow empty interior chamber'or void, and which results in a single piece brim having a longitudinally seamless and relatively thick edge or rim, that is, without .lon tudinal or circumferential seams exten ing around the-rim or outer edge thereof, as is usual inthe art. By cushion brim, is meant a brim having an upper brim and alower brim and edge or a to a facing and an ed e which is formed 0 j a foundation of sti ening material such as buckram and a cloth covering,

is requiringthe centers both the foundationand the covering beingfolded-in the middle or equi-distantly between the opposite edges of the band or ring into which the strip forming the'same made, so that the same can be made each of a single piece of material with the facing, edge and top continuous, thereby producing a circumferentially seamless edge which may be' shaped in any suitable manner by blocking and stretchingas is common in the art.

rim than at the inner ed e,-so as to taper inwardly or increase in t ickness outwardly, as regards the cross section of the brim.

In the old method of making hats of the type or style to which this invention appertalns, separate upper and lower pieces are used to make .the foundation or stiffening and separate upper and lower rectangular pieces are used to form the covering including the top and facing, While the edge or edging at the rim is formed with or consists of a joint or seam as a resultof the edges of the material being brought together. The

pieces are pasted together and blocked, thus and corners to be cut off to fit the head and produce the desired shape, and the material at the edge or rim is folded or. wired so that a seam is produced with a brim having a relatively flat cross section. With' the present construction and improved method of making hats and hat brims edge and facing and back to the crown,

V The brim in the form shown is thicker at the outer edge or so' is the covershape, so as to produce a cushion and double brim without longitudinal seamsor stitches and of hollow tubular cross-section and the two being 1- empty, to form a void within' jthe top and bottom portions "being spaced apart and disconnected at the inside and the edgeor rim shaped as desired, but essentially seamless irrespective of its shape cross sectionally.

Thus, the foundation or stiffening and the covering", and so the brim as an entirety roduced therefrom is continuous from the ase' of the crown'at the headsi'ze over the top,

inner edges'orportions of the brim top and facin .being brought together and in contact or association, with and attachment to the crown at the base and the lining. It should be noted that in addition to being of hollowtubular form to produce a brim with the top and bottom portions spaced apart and disconnected at the inside between the outer either by stitches, paste orotherwise, and with the foundation or stif-.

and inner edges,

the

fening, and the covering similarly shaped,

each is smoothly and over the top, edge and bottom cross sectionally of the brim and of inwardly tapered, streamline, wed e shaped or'doubly convex cross-section, thereby presenting athick outer edge or rim and an attractive and pleasing soft cushion appearance.

What I claim is: 1'. A 'hat having a hollow cushion brim, said brim com'prisln a strip having itsends connected to form a and, said band having a stiffening medium extending throughout its entire area, portions at each side of the medial line betweenthe opposite edges of said band being brought toward each other in inwardly convergent relation to form a hollow flexible cushion brim with a relatively thick rim and a single'interior-void. 2. A hat brim comprising a covering and a stifiening medium for and carried by the same and extending throughout'the entire area thereof, the brim being devoid of filling and the material of the brim .eXtending continuously over the top, rim and bottom radially in folded hollow relation.

A hat having a brim comprising a cov- .ering bandfolded at the rim, a stiffening ating free of seams runningaround the-same circumferentially.

4. A hat-comprising a crown and a brim,

continuously vextendedsaid brim comprising a stifi'ened reinforced covering, the stiffening and covering being folded to extend continuously over the top, edge and bottom of the brim,'with an interior empty chamber within the covering and stiffening. a

5. A, brim havin a buckram foundation of hollow tubular form and a covering secured over the same, the material of the foundation and the covering each extending continuously over the top edge and bottom of the brim;

"6. A brim having a foundation of wedgeshaped cross section and devoid of filling, and a covering fastened smoothly against the foundation, the material of the foundation and the covering each consisting of a strip cut on the bias and joined at its ends to form a band and the material of the foundation and covering extending continuously and in one piece formation over the top, edge and facing of the brim except where the'ends are joined together, and the top and facing being spaced apart from the inner to the outer ed e.

A cushion brim comprising a body of relatively stifi material bent over on itself at the rim in hollow formation and a covering secured in conforming relation thereto adhesively over the top, rim and bottom, the rim being free of stitches connecting the top and bottom and also free of seams run-- ning around the rim longitudinally, said brim tapering in thickness from the rim to the inner edge Where attached to the crown. .8. A hat comprising a crown and abrim attached-thereto at the base, said brim comprising a stiffening foundation body of buckram or the like shaped'into rebent tubular form with a thick edge and spaced upper and under brim portions unconnected between the rim and inner edge and approaching each other toward the inner edge and a covering secured to the foundation body and smoothly conforming thereto 9. A hat brim of hollow tubular formation, said brim being formed of asingle section of material cut on the bias joined at its ends toproduee a band, said brim being free of seams extending around its circum-' ferential edge.

10. A hat brim with an edge devoid of longitudinal seams consisting of a strip of material having its ends- 'oined to form a band, and a foundation t erefor, said ma terial and foundation being continuous from the inner edge of the top and over the rim of the brim to the inner edge of the facing in a radial direction to present a seamless formation longitudinally and radially except at the ends of the strip joined to form the band.

11. A hat construction comprising a brim formed of a single sheet of material having a lining of stiffening material bent upon itself to form spaced upperand lower layers of material and a relatively thick edge at the rim, the layers being'spaced apart at the rim and approaching each other toward .their inner edges, said rim being smooth, and

therefor, said. covering and body portion consisting each of a band having its ends joined together to form a seam and the seam of the covering extending at an angle to theradius of the brim, I

13. A hat having abrim consisting of a foundation and a covering, the foundation and covering each consisting of asingle band folded equi-distantly between the opposite edges thereof in substantially U-shaped formation, the covering being secured on the foundation and both attached to acrown, the

material forming the-top, facing and edge of the brim extending continuously and uninterruptedly from the inner edge of the top over the rim edge of the brim and to the inner edge of the facing, the rim being hollow and forming an empty chamber within.

14. A method of making hat brims consisting in blocking and stretching a band of coverlng material having a reinforcing and stiffening medium into substantially channel-shaped cross section to form a closed rim and spaced inner edges for attachment to a crown.-

15'. A method of bat construction consisting in taking a. foundation of stiffening material in the form of a' band and blocking the same into substantially U-shaped channeled formation continuous from one inner edge to the other inner edge, at least one inner edge being provided with aflange extending substantially at right angles thereto to form the head size: for attachment to a crown, and covering said foundation.

16. A method of hat construction consisting in taking a foundation of stiffening material in the form of a band and blocking the same into substantially U-shaped channeled formation continuous from one inner edge to the other inner edge, at least one in- I ends thereof together to form bands and blocking the same in folded or.U-shaped form in cross-section and stretching the covering over the foundation produced by the 5 buckram.

18. A method of making hat brims consisting in forming bands of foundation material and covering material cut on the bias, blocking the same in folded form and 10 stretching the covering snugly and smoothly over the foundation, the material being continuous over the top, rim and faclng, and

the .opposite edges of the material being v formed into'fia nges one of which is the head slze.

' 19. method of making brims for hats of the class described consisting inblocking a band of buckram into substantially [h shaped cross section with a covering band of cloth 'thereover, the opposite edges being brought in proximity to each other and 

